Multi-core Cable Heat Detection via Differential Insulator Melting
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Solution Overview
Problem
Conventional multi-core cables used for contactless power supplies lack effective temperature rise detection, which can lead to fires due to excessive current flow, necessitating a solution to accurately monitor temperature increases.
Innovation Solution
A multi-core cable design incorporating a heat detection line with twisted pair wires and electric wires spirally twisted around it, where the first insulator has a lower melting point than the second insulator, allowing for sensitive temperature detection through conductor contact and resistance changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-core cables are used for contactless power supplies, then power transmission function is achieved, but temperature rise detection capability is lacking leading to fire hazard
Solution Approach 1:
The patent combines the heat detection function and power transmission function into a single integrated cable structure. The heat detection line (twisted pair wires with low melting point insulator) and electric wires (with high melting point insulator) are merged within one sheath, allowing simultaneous temperature monitoring and power transmission without requiring separate detection cables.
Solution Approach 2:
The patent applies different melting points to different insulators based on their functional requirements. The first insulator (heat detection line) uses a low melting point material to enable sensitive temperature detection, while the second insulator (electric wires) uses a high melting point material to ensure power transmission safety. This local differentiation of material properties enables both functions within the same cable.
2Measurement precision
If heat detection line is added to multi-core cable, then temperature detection accuracy is improved, but cable structure complexity increases
Solution Approach 1:
The heat detection line is integrated within the same sheath as the electric wires, combining multiple functions (temperature detection and power transmission) into a single cable assembly. This reduces the need for separate detection cables and simplifies overall system installation while maintaining detection accuracy.
Solution Approach 2:
The patent changes the melting point parameter of the first insulator to be lower than the second insulator, enabling the heat detection line to respond to temperature changes before the power transmission wires are affected. This parameter differentiation allows accurate temperature monitoring without interfering with the power transmission function.
3Measurement precision
If low melting point insulator is used in heat detection line, then temperature sensitivity is improved, but risk of premature short circuit increases
Solution Approach 1:
The patent assigns different melting points to different insulators based on their specific functions. The first insulator uses a low melting point material optimized for temperature detection sensitivity, while the second insulator uses a high melting point material optimized for power transmission reliability. This local quality differentiation ensures that the heat detection line responds to temperature changes before the power transmission wires are compromised.
Solution Approach 2:
The heat detection line acts as an intermediary system that detects temperature changes and provides early warning before the main power transmission wires are affected. The low melting point first insulator serves as a protective intermediary that triggers detection before the high melting point second insulator would fail, preventing catastrophic short circuits in the power transmission system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate detection of temperature rises in the multi-core cable, preventing potential fires by triggering a short circuit when the first insulator melts, thus ensuring reliable operation and safety in contactless power supply systems.
Implementation Method 1
a melting point of the first insulator is lower than a melting point of the second insulator
Implementation Method 2
the electric wires (power lines) provided within the multi-core cable receive a large current flow. Therefore, there is a demand to suppress the rise in temperature in the multi-core cable
Data Source
AI summary
A multi-core cable includes a heat detection line including a twisted pair wire composed of a pair of heat detecting wires being twisted together, each of which includes a first conductor and a first insulator covering a periphery of the first conductor, a plurality of electric wires spirally twisted around the heat detection line, each of which includes a second conductor and a second insulator covering a periphery of the second conductor, and a sheath covering the heat detection line and the plurality of electric wires together. A melting point of the first insulator is lower than a melting point of the second insulator. The second conductor has a shape in a cross-section perpendicular to a cable longitudinal direction in which a width along a circumferential direction is gradually increased from a radially inward portion to a radially outward portion.